Thread: Need some advice TIG welding used stainless exhaust

dont worry guys i'll just use exhaust bog/putty, sand than paint it

Weld, linish > finishing with scotchbrite, then buff.

For that sort of stuff, I use a caustic bath that removes carbon/oils/etc. Probably could mechanically clean or blast it though. Muffler packing, doesn't look like there's a removable end to access that, so you'd have to cut the cap weld. For the effort required I probably go to a wrecker and buy a second-hand one of the appropriate size, unless you're particularly attached to that one.

Surprising thing, a lot of the Chinese stuff we bring in uses Russian stainless, so either it's cheaper than the local stuff.....and they'll sell their sister to save a few cents.....or local product is really cr@p!

thanks hutch i can only find one exhaust from a wreckers and its been scratched badly

Was thinking along the lines of a generic muffler, there's probably a small mountain of stock mufflers sitting out there somewhere, that have been replaced by noisy go-fast versions in carbon or titanium. Looking at the angle grinding, no doubt the perforated tube inside is in a couple of bits too.

Hutch i thought about that too but if u look at my picture to the very far right you'll see a small vent pipe, this vents into the exhaust i have never seen on another bike and actually a lot of air comes out of this pipe

generic exhaust dont have this pipe

What about wrapping it in a thin stainless sheet ? Not ideal, but it will work

Originally Posted by DocBug

What about wrapping it in a thin stainless sheet ? Not ideal, but it will work

Thanks for the idea Doc the bike will need to go for a blue slip registration inspection so they'll probably knock it back on that

Hi Gaza,

Thanks for the reply, i was thinking wrap and weld it so it looks original, just without the pressed name.

Sounds like a cat or an old style air injection....which might offer some explanation for the bizarre cutting, no chance it clogged?

Hunch i might actually go with your idea on the generic muffler, i was looking on ebay trying to find a aluminum muffler off a bigger bike, seeing as im hacking up the bike i thought it would be a good time to chance hacking a 1000cc-1200cc bike muffler i could make it a "Shorty" muffler im ok welding aluminium but unsure how i would make a pipe reducer to join the stock 35mm exhaust pipe to the new muffler than it'll just be a matter of welding on the smaller vent pipe

if i was to hack the big bikes muffler i could clean inside the cut for welding

i suppose the same could go for a stainless steel muffler too as long as i make it a shorty but ive never welded SS

looking at the exhaust below is very cheap and disposable just unsure if its polished aluminium or SS